Method and apparatus for manufacturing an implant

• US 9,907,659 B2
• Filed: 02/13/2009
• Issued: 03/06/2018
• Est. Priority Date: 04/17/2007
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Belcher, Nathan Emick, Metzger, Robert
• Primary Examiner(s): Seoh, Minnah L
• Assistant Examiner(s): WILLIAMS, TERESA S
• Application Number:
  US12/371,096
• Publication Number:
  US 20090151736A1
• Time in Patent Office: 3,308 Days
• Field of Search: 705 2, 705 3, 700245, 600424, 600587, 623 2014
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2002/30616 Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30708 Means for distinguishing between left-sided and right-sided devices, Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2002/3071 Identification means; Administration of patients
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30953 using a remote computer network, e.g. Internet
• CPC Class Codes: A61F 2002/4633 for selection of endoprosthetic joints or for pre-operative planning
• CPC Class Codes: A61F 2250/0084 Means for distinguishing between left-sided and right-sided devices; Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2250/0085 Identification means; Administration of patients

Abstract

An orthopedic implant manufacturing method. The method includes preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane, communicating the surgical plan to a surgeon of the patient, and receiving approval of the surgical plan and the resection plane by the surgeon. The method also includes providing automated osteophyte/protrusion removal control for surgeon manipulation, receiving a modified three-dimensional image of a patient'"'"'s joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon, and requesting manufacture of the selected orthopedic implant.

Claims

1. An orthopedic implant manufacturing method comprising:

preparing a pre-operative electronic surgical plan for a specific patient, the electronic surgical plan including a three-dimensional image of a patient'"'"'s joint indicating a resection plane, the electronic surgical plan viewable on an electronic screen;

communicating the electronic surgical plan in a digital form to a surgeon of the patient;

receiving approval of the surgical plan and the resection plane by the surgeon;

providing electronic automated control of removal of an image of an osteophyte for electronic manipulation of the three-dimensional image of the patient'"'"'s joint on the electronic screen;

receiving a modified three-dimensional image of the patient'"'"'s joint indicating electronic removal of the image of the osteophyte on the modified three-dimensional image of the patient'"'"'s joint in the electronic surgical plan and a recommendation for a corresponding selected orthopedic implant from the surgeon; and

manufacturing the selected orthopedic implant by transforming an article to correspond to the modified three-dimensional image of the patient'"'"'s joint.

2. The method of claim 1, further comprising identifying a location of the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

3. The method of claim 2, further comprising providing a plurality of electronic depth contours in relation to the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

4. The method of claim 3, further comprising providing at least one electronic removal tool associated with the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan for manipulation by the surgeon.

5. The method of claim 3, wherein the plurality of the electronic depth contours is continuous.

6. The method of claim 5, further comprising referencing the plurality of the electronic depth contours from a landmark location associated with the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

7. The method of claim 2, further comprising determining a tissue overhang protruding from an edge of the resection plane on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

8. The method of claim 1, further comprising receiving a recommendation for a selected patient-specific alignment guide from the surgeon.

9. The method of claim 8, further comprising manufacturing the selected patient-specific alignment guide and providing the patient-specific selected alignment guide and selected orthopedic implant to the surgeon in one package.

10. The method of claim 1, wherein the selected orthopedic implant is a femoral joint component.

11. The method of claim 10, wherein the femoral joint component is custom made for the specific patient.

12. The method of claim 10, wherein the femoral joint component is semi-custom made.

13. The method of claim 1, wherein the selected orthopedic implant is a tibial joint component.

14. The method of claim 13, wherein the tibial joint component is custom made for the specific patient.

15. The method of claim 13, wherein the tibial joint component is semi-custom made.

16. An orthopedic implant manufacturing method comprising:

preparing a pre-operative electronic surgical plan for a specific patient, the electronic surgical plan viewable on an electronic screen and including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane;

communicating the electronic surgical plan to a surgeon of the patient;

receiving approval of the electronic surgical plan and the resection plane by the surgeon;

identifying on the electronic screen a location of at least one image of an osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan;

providing a plurality of electronic depth contours in relation to the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan;

providing at least one electronic graphical removal tool associated with the image of the osteophyte for electronic manipulation by the surgeon on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan;

receiving a modified three-dimensional image of the patient'"'"'s joint indicating removal of the image of the osteophyte on the modified three-dimensional image of the patient'"'"'s joint in the electronic surgical plan and a recommendation for a corresponding selected orthopedic implant from the surgeon; and

manufacturing the selected orthopedic implant by transforming an article to correspond to the modified three-dimensional image of the patient'"'"'s joint.

17. The method of claim 16, wherein the plurality of electronic depth contours is continuous.

18. The method of claim 17, further comprising referencing the plurality of electronic depth contours from a landmark location associated with the osteophyte on the modified three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

19. The method of claim 17, further comprising determining a tissue overhang protruding from an edge of the resection plane on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan.

20. The method of claim 17, further comprising receiving a recommendation for a selected alignment guide from the surgeon and manufacturing the selected alignment guide.

21. An orthopedic implant manufacturing method comprising:

preparing a pre-operative electronic surgical plan for a specific patient, the electronic surgical plan viewable on an electronic screen and including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane;

identifying a location of at least one image of an osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan;

providing a plurality of electronic depth contours on the electronic screen in relation to the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan;

providing at least one electronic graphical removal tool associated with the image of the osteophyte on the three-dimensional image of the patient'"'"'s joint in the electronic surgical plan for manipulation by a user on the electronic screen;

communicating the electronic surgical plan to a user;

receiving a modified three-dimensional image of the patient'"'"'s joint indicating removal of the image of the osteophyte on the modified three-dimensional image of the patient'"'"'s joint in the electronic surgical plan and a recommendation for a corresponding selected orthopedic implant from a user; and

manufacturing the selected orthopedic implant by transforming an article to correspond to the modified three-dimensional image of the patient'"'"'s joint.

22. The method of claim 21, further comprising

forwarding the selected orthopedic implant for implantation.

23. An orthopedic implant manufacturing method comprising:

generating preoperatively a three-dimensional computer image of a patient'"'"'s joint from imaging information obtained from the patient on an electronic screen;

generating preoperatively a modified three-dimensional computer image of the patient'"'"'s joint by removing an image of a bone protrusion shown in the three-dimensional computer image of the patient'"'"'s joint using a computer graphical tool on the electronic screen;

selecting an orthopedic implant corresponding to the modified three-dimensional computer image of the patient'"'"'s joint; and

manufacturing the selected orthopedic implant by transforming an article to correspond to the modified three-dimensional image of the patient'"'"'s joint.

24. The method of claim 23, further comprising receiving approval of the modified three-dimensional computer image of the patient'"'"'s joint before manufacturing the orthopedic implant.

25. The method of claim 23, wherein the bone protrusion is an osteophyte.

26. The method of claim 23, further comprising superposing an orthopedic implant image on the modified three-dimensional computer image of the patient'"'"'s joint on the electronic screen before selecting an orthopedic implant.